Performing wire Repair

A wire harness may be tape wrapped or enclosed in a plastic conduit. If it is conduit encased, simply open the conduit and pull out the desired wire. If the harness is tape wrapped, a seam splitter should be used to open the harness. This prevents damage to the insulation of the wire inside the harness. Seam splitters are readily available from sewing supply stores.
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Copper Wire Repair

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Step one: Open the Harness

If the harness is taped, remove tape with a seam ripper.

Use the blade with the pointed end to start a start a small slit in the tape away from any wire. Use the Blade with the rounded end to slit the tape as far as necessary. Be careful to avoid cutting into any wire insulation.

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Step one: Open the Harness

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Step Two: Cut Wire

Leave as much wire on the harness as possible. The splice should be at least 40mm (1 inches) away from any other splices or outlets.

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Step three: Strip Insulation

Find the wire size:

From the schematic (metric). Using a wire gauge ( AWG). See figure 5-8

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Wire stripping
Hold both handles in right hand, with gripper jaw to the left. Hold wire in left hand and press end against guide and up into correct notch of upper blade. Close left handle first, to grip wire firmly before cutting the insulation. Check stripped wire for nicks or cut strands. If the wire is damaged, repeat the procedure.
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Wire stripping

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Step Four Crimp Wire

Select the correct anvil on the crimping tool.

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Step Four Crimp Wire

Overlap the two stripped wire ends. Center the splice clip over the stripped wire.
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Step Four Crimp Wire

Crimp splice with crimping tool.

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Step Five: Solder

Apply 60/40 rosin-core solder to the hole in the back of the clip.

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Step Five: Solder

Follow the manufacturers instructions for the solder equipment you are using.

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Step Six: Shrink tubing

Center the shrink tubing over the wire splice. Heat the shrink tubing.

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Aluminum Wire Repair

Step One: Open the Harness

Because the harness has a plastic conduit, simply pull out the desired wire.

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Step Two: Cut the wire

Begin by cutting as little wire off the harness as possible. Splice locations may have to be adjusted to make certain that each splice is at least 40mm (1 1/2) away from other splices, harness branches, or connectors.
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Step Three: Strip the Insulation

When replacing a wire or lead, use a wire of the same size as the original wire, or larger. Look up the size on the schematic. Use wire strippers of the proper gauge. Be careful not to nick or damage the wire.
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Step Four: Crimp the Wires

Select the propersize splice clip. Place one wire end in each end of the splice clip. Crimp the clip firmly.
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Step Five: Coating the Splice

To prevent corrosion, apply a generous coating of petroleum jelly to the splice area. If replacing a lead, also thoroughly coat the terminal crimp area and aluminum core with petroleum jelly.

College of Marin Ron Palmer

Step Six: Shrink tubing

Center the shrink tubing over the wire splice. Heat the shrink tubing.

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Weather Pack Repair

Splicing a new terminal

Cut the wire immediately behind the cable seal. Slip the new cable seal onto the wire and push it back out of the way. Strip 5.0mm (3/16) of insulation from the wire.

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Splicing a new terminal

Crimp the new terminal over the copper strands. Use a stander crimping tool. Solder with rosin core solder. Move the cable seal to edge of the insulation. Crimp the grips at the end of the terminal.
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Splicing a new terminal

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Connector Repair

Step One: Separate the Connector Halves

To separate a large connector, unscrew the bolt in the center of the connector body. To separate a small connector, simply pull the two halves apart.

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Step Two: Remove the Terminal

To remove a terminal retainer, press a wire pick at a 45* angle against the locking nib. Then, pull the retainer out. To open the secondary lock on small connectors, flip down the lock hinges.

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Step three: Remove the Lead

Push the wire pick into the terminal hole. Depress the terminal locking tang using a wire pick. Gently pull out the lead from the back of the connector body.
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Step Four: Re-Form the Locking Tang

If the lead and terminal are in good condition, reform the locking tang. Hold the lead firmly to prevent the splice between the terminal and the wire from flexing. Use the pick to bend the locking tang back into its original shape. Check to see that the remainder of the terminal is in original shape.
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Step Four: Re-Form the Locking Tang

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Step Five: Make the Repair

When making a repair, use the correct types of terminals, wire and seal. To add a new lead, cut the wire and crimp and solder on the new lead using rosin core solder.

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Step Six: Insert the Lead

Make certain that the terminal is correctly shaped. Gently insert the lead from the back. The terminal should stop or catch about halfway through the connector body. Gently push back and forth on the lead to be sure the terminal is held in place.
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Step Seven: Replace the Terminal Retainers

Replace the terminal retainers by slipping the retainer haves into the connector body. To close the secondary locks on small connectors, flip the hinges back to their original positions.

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College of Marin Ron Palmer

College of Marin Ron Palmer

College of Marin Ron Palmer